Container



June 17, 1952 G. HAMMOND 2,600,989

CONTAINER Filed July 24, 1945 v v 5 Sheets-Sheet 1 IO 15, 1 x

)2 I4 '48 |6 m 14 i 32 & 38' 24 38 is 2 22 I8 his All'ol'lzeg June 1952 G. HAMMOND 2,600,989

CONTAINER Filed July 24, 1945 5 Sheets-Sheet 2 INVENTOR. Gordon Hammazzd his All'ofney G. HAMMOND June 17, 1952 CONTAINER 5 Sheets-Sheet 5 Filed July 24, 1945 INVENTOR. Ham 012d his All'or'neu June 17, 1952 G. HAMMOND 2,600,989

CONTAINER Filed July 24, 1945 5 Sheets-Sheet 4 INVENTOR. aai a mz Hammond G. HAMMOND June 17, 1952 INVENTOR. @0121012 Hammond Patented June 17, 1952 CONTAINER Gordon Hammond, Ashland, Va., assignor to Reynolds Metals Company, Richmond, Va., a

corporation of Delaware Application July 24, 1945, Serial No. 606,801

3 Claims.

It is an object of this invention to provide a rectangular container formed from a single sheet of metallic foil.

It is a further object of this invention to provide a container as aforesaid which optionally may be so closed as to be sift-proof without, however, being hermetically sealed, or, if desired, hermetically tight seals may be applied.

It is a further object of this invention to provide an improved method of forming such containers and of closing such containers after filling same.

superficially considered, many of the structural details of this improved container will appear to duplicate the details of existing closures for bags and containers where such bags and containers are formed of paper or cardboard. The resemblance, however, is superficial, since the nature and characteristics of metallic foil differ so markedly from those of paper or cardboard as to create an entirely unique type of problem. For example, caliper for caliper, aluminum foil, if tempered at all, is stiffer than paper or board. Moreover, any metallic sheet of a caliper sufliciently low and ductility sufliciently reat to be classified as a metallic foil is automatically thinner than all but the very lightest grades of paper and, of course, is thinner than any grade of cardboard. Another marked distinction lies in the fact that a very much smaller amplitude of deformation is required to produce apermanent set in foil than is required in paper or board. A further distinction lies in the fact that for all practical operating purposes metallic foil may be considered uniform in all dimensions; whereas, in all grades of paper and board, and particularly in those produced on the Fourdrinier machine, there is a marked difference both in strength and in stiffness between machine direction and cross direction. The effect of the above distinctions will be discussed hereinafter in .greater detail as such distinctions affect the package structure and the steps of forming and closing the same.

This invention will best be understood from the following detailed description taken in connection with the annexed drawings in which:

Figure 1 is a schematic view illustrating the initial step in the formation of the container body;

Fig. 2 shows the completion of the container body and the preliminary step in the formation of the longitudinal seam;

Fig. 3 shows the next step in the formation of the longitudinal seam;

Fig. 4 is a partial perspective view showing an open end of the container body with the longitudinal seam complete;

Fig. 5 is a perspective View showing the step for the preliminary formation of a closure;

Fig. 6 is an elevation showing the action of the parts illustrated in Fig. 5 as viewed from the major dimension of the container;

Fig. 7 is an elevation at right angles to Fig. 6;

Fig. 8 is an elevation similar to Fig. 7 showing the next step in the formation of the closure;

Fig. 8a is a view similar to Fig. 8, but showing an alternate means for performing the step of Fig. 8;

Fig. 9 illustrates the preliminary folding of the central closure seam;

Fig. 10 illustrates the completion of the first fold in the central closure seam;

Fig. 11 illustrates the preliminary formation of a second fold in the central closure seam;

Fig. 12 illustrates the completion of the second fold in the central closure seam;

Fig. 13 illustrates the step of folding the central closure seam into the plane of the end of the package;

Fig. 14 is a, perspective view showing the completed package;

Fig. 15 is a schematic diagram illustrating in series the combination of the steps illustrated in the detailed Figures 1 through 13; and

Fig. 16 is a perspective view illustrating an optional preliminary treatment of the blank from which the container is formed.

Metallic foil is customarily provided in continuous rolls of indefinite length. A strip of foil is fed from these rolls and subjected to repeated printing operations in order to provide what will ultimately become individual container blanks with suitable advertising or other external indicia. Depending on the ultimate use to which the container is to be put, it may be desired to coat one or both sides with a lacquer having particular physical or chemical properties. Over all coating for the interior of the package will usually be done as a separate operation and the web rewound. External coating to overlie the printing, or to provide localized coated areas will usually be a concomitant of the printing steps.

In Fig. l a blank [0 suitably printed and/or coated has been cut from the continuous web and has been partially formed around a mandrel I2 by means of folding bars [4. This defines a front wall [6 and side walls l8 of a rectangular container body.

In Fig. 2 folding arms 20 have been brought in contact with side walls [8 while extensions 26' of the members have brought the free margins of the blank [0 against the mandrel l2 to form a rear wall 22. The opposed margins of the blank [6 form an upstanding fin 24 which is rolled on to one of the extensions 26 by a pressure roller 26. This forms a crease 28 in the fin 24.

The portion of the fin 24 which is folded against one of the members 26' is designated 36 and has a length slightly greater than the thickness of the extension 26' against which it is folded. It will be understood that in practice, the mandrel I2 is advanced from one station to another through a series of stations. The operation illustrated in Fig. l is performed at the first station and a clamping member 32 is brought to bear against the front wall Hi to hold the partially formed container around the mandrel l2 as the mandrel advances from station to station.

Fig. 3 shows a further development of the longitudinal seam. Here, a special pressure member 36 bears against one of the walls l8 and has an extension 36" overlying a portion of the rear wall 22 and supporting one side of the seam 24. A second member 38 bears against the opposite side wall [8 and has an extension 38 which is brought, first into engagement with the turnover portion 30 of the fin 24, pressing the seam against the extension 36' of the member 36, and also against the rear wall 22 and, of course, the mandrel l2. The next step is the conventional one of flattening the remaining upstanding portion of the seam 24 against the rear wall 22 to bring the parts to the condition illustrated in Fig. 4. As shown in Fig. 4, the seam 24 is grossly exaggerated in thickness. Metallic foil of the type here contemplated will have a caliper preferably of .003", and even the multiple folds involved in the seam 24 do not build up a substantial overall thickness. When the seam 24 is crushed fiat, the labyrinth joint provided presents a perfect hermetic seal. Fig. 4 particularly illustrates the fact that a rectangular container body is formed having completely unbroken margins at the open ends. The solution of the problem of closing these open ends will now be discussed in connection with Figs. 53-14, inclusive.

Following completion of the seam 24, the container body portion is slid upwardly along the mandrel to leave a margin of material unsupported by the mandrel of sufiicient depth inwardly from the free unbrokenedge to permit the formation of the closure hereinafter described. The I55 first step in the treatment of this unsupported margin is shown in Fig. 5. The mandrel extends only to the fold lines 40 and 42. A pair of pressure members 44 approach the upstanding portions of the front wall [6 and the rear Wall 22 while another pair of pressure members 46 approach the side walls I8. The members 46 initiate gusset folds in the free margins of the side walls l8, while the members 44 bend the upstanding margins of front and rear walls I6 and 22 toward each other. As above noted, a relatively mild deformation, produced by the pressure members 44 and 46 suflices to give the various walls a permanent set in the ultimate position to which such walls are brought by the pressure members 44 and 46.

Fig. 6 details the action of the members 46, while Fig. 7 details the action of the members 44. The members 46 in cross section are equilateral triangles. The active ends have a bevel 48 which makes an angle preferably of substantially degrees with the horizontal. The apex 56 of the bevel 48 lie below the apex of the cross section of the members 46 and is joined to the apex of the cross section of the members 46 by a vertical line. The material of the members 46 is beveled intermediate the plane of the bevel 48 and the apex of the cross section of the member 46 to provide a pair of triangular areas. As the members 46 advance upon the side walls [8, the apices 56 0f the bevels 48 thrust the centers of the side walls inwardly initiating a pair of gusset folds. At the same time the members 44 advance upon the front Wall I6 and the rear wall 22 to the position shown in Fig. '7, giving the margins of the front and rear walls a permanent set at the angle indicated in Fig. 7.

With the mouth of the container in the condition to which it is brought by the parts illustrated in Figs. 5, 6, and '1, the container moves to a station of either of the types indicated in Figs. 8 and 8a. In Fig. 8 there are shown two members 52 each having a pivot 54 in the plane of the fold lines 42. The members 52 are actuated by any suitable means, such, for example, as the rods 56. When the container enters this station, the members 52 are in their dotted line position. The rods 56 then advance toward the front wall I6 and the rear wall 22 of the container and thereby rock the members 52 about the pivots 54. This crushes the mouth portion of the container into the plane of the fold lines 42 but leaves an upstanding fin 58 extending centrally along the bag mouth and of a length equal to the width of the front and rear walls. Each end of the fin 58 contains a gusset fold formed from the material of the side walls l8. In Fig. 8a the same effect is secured by reciprocating members 60 which move from the dotted line position of Fig. 8a to the solid line position and which produce an identical fin 58.

From a station of the sort indicated in Figs. 8 and 8a, the container proceeds to a station arranged in accordance with Fig. 9. At this station a member 62 slides across the top of the container and engages one side of the fin 58 supporting it from its base to a point approximately midway of its height. A second member 64 engages the opposite side of the fin 58 at a point very slightly higher than the top of the member 62. A roller 66 then moves across the upper surface of the member 64 and folds the free portion of the fin 58 around an edge 68 of the member 62.

With the fin 58 in the condition illustrated in solid lines in Fig. 9, the container moves to a station of a type indicated in Fig. 10. Here, a member 16 engages one side of the fin 58 and member l2 pivoted at 14 swings toward the fin 53 to crimp the fold initiated by the station of Fig. 9.

With the fin 58 in the condition illustrated in solid lines in Fig. 10, the container is moved to the station illustrated in Fig. 11. This station, it will be noted, is substantially identical with the station of Fig. 9. A member 16 having a folding edge 18 engages the fin 58 just below the turned down edge of the fold which was completed at the station illustrated in Fig. 10. A second member 86 engages the opposite side of the fin 58. A roller 62 moves to the dotted line position and initiates a second folding of the fin 58 to its dotted line position in Fig. 11.

With the fin 58 in the condition illustrated in clotted outline in Fig. 11, the container moves to a station of the type illustrated in Fig. 12 which tight, although it is entirely sift-proof.

station issubstantially the same as the station illustrated in Fig. '10. Here, a member a ienagesthe rear-'sideof the fin while a member 81i, pivoted at 68, swings down to complete the foldingofthe-fin. l

'Fromthe station iliustratedin Fig. 12,'the'container'moves to a stationto such as'is shown in Fig. 13. Here, arel-atively thin, stiff plate 90 slides across the toner" the bag and engages the bottom of the-fin 'dt while a roller' 92 moves in the opposite direction to fold thefin 53 flat against the topof the container. It'will'be-understood that the thickness-of "the 'fi'nally folded fin 58, as illustrated in Fig. 13, is grossly exaggerated. Using metallic foil of .005" caliper or lessymultiplication'of theplies still fails to build up any substantial or objectionable thickness.

The completed'container is shown in Fig. l i. It will be noted that the longitudinal seam 24 which lies on'the rear of wall 22, enters into the closure fin 58. If it were not for the presence of the seam 24 and of the gussets extending inwardly from the side walls 48, the folded fin 58 would form a sufficient labyrinth to provide hermetic sealing. The diiferential thicknesses causedby the presence of'theseam Z4 and-o'fthe gussets, prevent the closure being entirely gas This, however, is highly desirable for a great"r.oany uses to which the container may be put. For example, in the packing of frozen foods, it is frequently necessary that the package permit venting, either inwardly or outwardly, due to expansion or contraction of the air within the package during the rather extreme temperature changes which take place. In addition, the present package offers the very great advantage that a frozen food may be removed from the freezer and'cooked in the package itself before the package is opened. forms a sufficient vent to avoid the generation of substantial internal pressure during the cooking process. Such pressure as is developed, however, is internal, so that the cooking water surrounding the package does not enter to dilute the normal juices produced by the cooking of the food.

The fact that the package is formed of metallic foil produces great economies in the freezing process, since the greater conductivity of the package walls shortens the freezing time materially.

The formation of the end closure has been described above with reference to the formation of the initial or bottom closure, and since this is done with the internal support of the mandrel I2, the formation of the closure probably does not appear to present any very remarkable difliculties. After the package is filled, however, there cannot be the type of support for the walls which is afforded by the mandrel i2. In order to form the final or top closure, the Package is filled and inserted into a supporting form which then carries the package through precisely the steps described in connection with Figs. 5-13, inclusive. This would be impossible of accomplishment in a container made of either paper or cardboard. As a matter of fact, a top closure may be formed by this process even when the package is completely empty. So far as applicant is aware, the closure illustrated herein has never been formed from cardboard, and while superficially similar closures have been made from flexible paper, such closures have always been made utilizing:

This type of closure Firsts-n sharp .preliminary creasing of the walls, atleast'in tlieregion'of the mouth to determinethe formation'of the gussets; and Second-Reliance has "always been placed on the support of the contents in turning down the final fold.

Whenfor-anyreason, complete hermetic sealingis desired, material of the type used to secure ordinary can topsmay be imprinted within suitable areas at the mouth before formation of the closure. As an alternative, either the mouth portions or the entire interior surface of the material may be coated with a thermoplastic substance and the final fin heat sealed. It is also possible when using aluminum foil to produce an effective hermetic heat seal by heating the foil itself to or near the fusion point and simultaneously applying pressure. Where the closure is to'be heat sealed, the heat and pressure are best applied at the station illustrated in Fig. 12.

Referring now to Fig. 15 there is shown the complete process from roll stock to a final filled and closed package. Metallic foil I is fed from a roll I02 and passes'through any suitablepreliminary treatments indicated generally at I04. Shears I66 sever individual blanks I08 which then pass through the longitudinal seam forming station designated in Fig. 15 by the legend Figs. 1, 2 and 3. The completed container body then passes to the preliminary closure forming station designated bythe legend Figs. 5, 6 and 7. The container then passes consecutively through the stations designated Figs. 8-13, inclusive. On leaving the station designated Fig. 13, the container arrives at a station Ill) at which air .jets l2 blow the container free from the mandrel "I2. The container is'then placed in aform made up of lateral guide rails II c and intermediate spacing blocks H6 which form a complete external support for the empty container. The container then is filled at a station designated I I8 through a spout I20. From the filling station H8 the container passes to a station I22 which duplicates the station at the container forming line above identified by legend Figs. 5, 6 and 7. The container then passes to a station I24 duplicating the station above identified as Fig. 8 and thereafter passes through stations I26 to I34, inclusive, corresponding respectively to the stations above identified as Figs. 9-13, inclusive.

Fig. 16 shows a web of metallic foil I50, the margins I52 of which have been deflected slightly of the plane of the central portion I54 along the score lines I56. This treatment may conveniently be accomplished at the station I94 in Fig. 16. When the blank is formed around a mandrel, the mandrel lies on the side of the blank toward which the portions I52 are deflected. Once the blank is formed around the mandrel, the deflection of the portions I52 becomes virtually imperceptible to the eye. Nevertheless, the crystalline and molecular structure of the sheet has been altered along the lines I56 and the folding of the ultimate end closures is thereby facilitated. This treatment is not indispensable in any case. It is, however, desirable and results in expediting the forming and closing process in cases where the container is fairly large, the intended contents fairly heavy, and the foil consequently relatively of heavier caliper.

For the purpose of illustration, certain of the structural details of the package have been minutely disclosed herein, but it is not intended to limit this invention to the precise details of the disclosure. For example, the rolling of the margins to form the longitudinal seam might be omitted and a butt welded or heat sealed lapped seam or any other type of interlock might be substituted in place of the structure shown. Similarly, the terms front, rear and side walls, and the terms top and bottom closures" are used for the purpose of reference and differentiation and not by way of limitation. The invention, therefore, is to be limited only as set forth in the subjoined claims which are to be broadly construed. I

I claim:

1. A method of making containers comprising: providing a sheet of unlaminated aluminum foil of a caliper not substantially less than .003" nor substantially more than .005"; folding said sheet simultaneously along two spaced, parallel lines not defined by preliminary scoring to form a front wall; then simultaneously folding said sheet along two additional spaced, parallel lines not defined by preliminary scoring, to form opposed side Walls and a rear wall; controlling the second folding operation to bring together in the rear wall opposite margins of the sheet in a fin normal to the plane of the rear wall, folding said fin upon itself and then into the plane of the rear wall to form a longitudinal seam and thereby a rectangular tube; and closing one end of said tube by folding the unbroken margins of all of said side walls into interlocked engagement in a fin and folding the fin to lie, with said closure, substantially in a single plane normal to the axis of the tube.

2. A container comprising a hollow, rectangular, self-sustaining parallelepiped formed from a single sheet of aluminum foil, free of any fibrous lamination of a caliper not substantially less than 0.003" not substantially more than 0.005", opposed margins of said sheet meeting in one wall of said container in face to face contact to form a fin, said fin being folded upon itself and then into the plane of said wall to form a longitudinal seam substantially parallel to the corners of said parallelepiped, the margins of said parallelepiped at the ends thereof being unbroken, a closure formed at at least one end of said parallelepiped and lying in a plane at right angles to the walls, said closure being formed by joining the unbroken margins at said end into a fin extending transverse the closure, said fin being folded upon itself and then into the plane of the closure and including a portion of said longitudinal seam.

3. A container as set forth in claim 2 having both ends closed in the manner set forth therein.

GORDON HAMMOND.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 663,133 Shipley Dec. 4, 1900 1,143,609 Bryner June 22, 1915 1,215,868 Rosenfeld Feb. 13, 1917 1,626,525 George Apr. 26, 1927 1,915,026 Meyer-Jagenberg June 20, 1933 2,066,304 Smith Dec. 29, 1936 2,102,858 Schlumbohm Dec. 21, 1937 2,169,173 Westin Aug. 8, 1939 2,241,943 Berch May 13, 1941 2,322,654 Moore June 22, 1943 FOREIGN PATENTS Number Country Date 218,355 Great Britain July 7, 1924 344,037 Italy Oct. 21, 1936 

